World Applied Sciences Journal 24 (10): 1399-1403, 2013

ISSN 1818-4952
© IDOSI Publications, 2013
DOI: 10.5829/idosi.wasj.2013.24.10.7020

Matrix Modeling of Technological Systems Grinding with Closed Circuit Ball Mill

Rashid Rizaevich Sharapov, Aleksandr Mikhailovich Agarkov and Rinat Rashidovich Sharapov

Belgorod State Technological University named after V.G. Shukhov, Russian Federation,
308012, Belgorod, Kostyukova, 46

Submitted: Aug 13, 2013; Accepted: Sep 11, 2013; Published: Sep 15, 2013
Abstract: Presented promising application of technological systems grinding cement clinker and additives on
the basis of the closed circuit ball mills. Matrix model transformation a grain structure in closed circuit ball mills
with design features included in the flow chart of elements allowing to predict grinding process parameters
(performance, power consumption, quality of the finished product, etc.) represented.

Key words: Ball mill Matrix of grinding Separator Aero material flows

INTRODUCTION Points with coordinates (dj, 1-seij) define the curve

Improving the efficiency of cement production is
possible by improving the technological everyone
conversions [1, 2]. One of the major in the production of
cement is a fine grinding cement clinker and additives in
various types of grinding devices. Despite the large
number of modern mills, some of the most simple in
construction and maintenance is ball mills, which are able
to obtain a finished product of the different properties of
clinker [1, 3, 4]. However, the absence of a generalized
method of calculating the entire grinding line complicates
both designing and the modernization and operation of
technology systems on the basis of grinding ball mills to
produce a quality product with a minimum of energy
consumption for grinding [5-7].
Closed grinding systems are complex groups of
elements and subsystems, interconnected material
and aero material flows. The basic element of system
is a ball mill, the efficiency of which is characterized by
(a lower triangular) grinding P matrix, each element of
which pij is equal to share of jth fraction of the material
entering the mill, which after grinding passes in the ith
fraction to the original product separator [8]. Separator
operating is characterized by a diagonal matrix separation
Se, each element of which seij shows the of share of the jth
fraction of the original material, which translates into the
same fraction of the finished product:
Q2 ∆Di2 (1)
Seii =
Q1∆Di2
Tromp for the separator. Aspiration take-out, operation of
the aspiration shaft, cyclones for the deposition of cement
and dust cleaning, bag filters and so on are
characterized by similar matrixes factional passes
(breakthrough). The fractional compositions of the
various material flows denote column vectors f with
appropriate index. Their elements are fi = Di is equal
relative to share of ith fraction of material (i = 1, 2,... m,
where the serial number m corresponds to the finest
fraction of the material). The number of fractions of the
material m determines the size of the matrixes of grinding
and the faction passes.
System of material and aero material flows in the
grinding flow chart ball mill-classifier (GFC "BM-S") are
shown in Fig. For each device are: the matrix
transformation of dispersion, the vectors of dispersed
composition and size of incoming and outgoing flows of
material and process air. The mass conservation
conditions are carried out for each machine and the
system as a whole:
Qc = Q2 + Qt, (2)
Qab+ Q(1)cb + Q(2)cb = Qbb. (3)
Here Qt - mass flow discharge of material into the
atmosphere; Qab, Q(1)cb, Q(2)cb Qbb - aspiration air mass
flow rates, air drawn to the line "mill-aspirated shaft-
cyclones-filter" in the chart "separator-cyclones” and also
a full flow of dusty air, discharged into the atmosphere.

Corresponding Author: Rashid Rizaevich Sharapov, Belgorod State Technological University named after V.G. Shukhov,
Russian Federation, 308012, Belgorod, Kostyukova, 46
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m
The task of the matrix modeling the grinding system
is to determine size and dispersion of material flow
Qa = Q1 ∑ f 1j aii (10)
i =1
through the load mill characteristics Qc and fc and the
transformation matrix particle size distribution in the mill, fi1aii
fi a = .
separator, cyclones and filters. m (11)
The matrix model of the closed grinding circuit ∑ f i1aii
i =1
(represented stepwise) will receive from the base of
balance equation ith narrow faction material during its Because of the of aspiration removal changing
mechanical processing in the elements and nodes of the number and dispersion of material coming out of the mill
system [3, 9]. [11, 12]:

Mixing the original material and grit entering the mill: Q1 fi1 (1 - aii) = (Q1 - Qa) fi(1), (12)

Qc + Qk = Qm; (4) where fi(1) - the contents of ith fraction to the grinding
product exiting the mill.
Qcfic + Qk fik = Qm fim. (5) The deposition of suspended material in the
aspiration-coagulation shaft described by the matrix:
Dividing both sides of equation (5) on the Qm = Q1, we get:
Qa fia sii = (Qa - Qs) fis ; (13)
1 c  1  (6)
f i + 1 −  f ik =fi m
kc  k c  (Q1 - Qa) fi(1) + Qa fia (1 - sii) = (Q1 - Qa + Qs) fi(2), (14)

where kc = Q1 /Q2 = Qm /Qc - circulation rate. where Qs - mass flow of the material deposited in the
aspiration shaft; fi(2) - the content of ith fraction in the
Grinding the material in a ball mill: material exiting the aspiration shaft.
Qm = Q1 , Cleaning the aspiration air in the cyclone
m
1
m
 1 
m characterized by a matrix of fractional breakthrough C =
=fi1 ∑ P= k
m
ij f j
c
∑
Pij f jc +  1 −  =
 k c 
∑
Pij f jk (cii):
=j 1 =j 1 =j 1
(7)
m
1 oc  1  (Qa - Qs) fis cii = (Qa - Qs - Qy) fiym; (15)
=
kc
fj +  1 − 
 kc  ∑ Pij f jk .
j =1
(Qa - Qs) fis (1 - cii) = Qy fiyk, (16)
Here,
m where Qy - mass flow of material deposited in the cyclone;
f joc = ∑ Pij f jc (8) fiym, fiyk - content of ith fraction in the material particles that
j =1 are carried along with the air from the cyclone and
precipitated in it.
the content of the ith fraction in the product at the open
circuit grinding mill. The merging of material flows after cyclones:
Forming of aspiration removal of the material is
characterized by the matrix A = (aii) [10]: (Q1 - Qa + Qs) fi(2) + Qy fiyk = (Q1 - Qa + Qs + Qy) fi(3). (17)

Q1 fi1 aii = Qa fia, (9) The merging of material flow at the inlet of the filter:

where Qa - the value of the aspiration removal of material;
fia - the content of the ith fraction of the material
suspended in the air aspiration. Summing both sides of all
factions (1 = i = m), we find the value and dispersion of
aspiration removal:
(Q1 - Qs - Qy) fiym + (Qo + Qoc) fio = Qbf fif, (18)
where Qbf = (Qa - Qs - Qy + Qo - Qoc) - the flow of material
entering into the filter; fif - the contents of the ith fraction
in it; Qo - the flow of material coming out together with the

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Fig. 1: The scheme of the material and aerodynamic flows in the flow chart of grinding "Ball mill-separator" with the
returning of dust cleaning products in the original material

air from the cyclone-precipitators. This flow at a Summing both sides of equation (20) for all the
point M (Fig. 1) branches in proportion to divide the factions, we find the power and content of all fraction of
airflow: the dust emission to the atmosphere:
(2) m
Qo − Qoc Qcb
= = p
Qoc Q fb
Qt = Qbf ∑ f jf fii (22)
i =1

Hence fi f fii
fi fm = .
m (23)
Qoc =
Qo (19) ∑ fi f
fii
1+ p i =1

The merging of material flows after the filter:

where Qoc - flow of material entering to the separator with
a separating air; p - the ratio of the leakage rate in the (Q1 - Qa + Qs - Qy) fi(3) + Qf fifk = (Q1 - Qa + Qs + Qy + Qf)fi(4) =
chart "Separator-cyclone-precipitators" to the volume of = (Qk + Qc + Qo - Qoc - Qt) fi(4). (24)
air separation.
Cleaning the dust-laden air in the filter is The merging of material flow at the inlet to the separator:
characterized by a matrix of fractional breakthrough of
particles F = (fii): (Qk+Qc+Qo-Qoc-Qt) fi(4)+Qoc fio = (Qk+Qc+Qo-Qt) fise, (25)

Qbf fif fii = (Qbf - Qf) fifm = Qò fifm; (20) where fise - the content of the ith fraction of the material
entering in the separator.
Qbf fif (1 - fii) = Qf fifk. (21) Separation of the material in the separator described
by the matrix classification Se = (seii):
Here Qf - mass flow of deposited material in the filter; fif, fifk
- the relative contents of the ith fraction of particles in (Qk + Qc + Qo - Qt) fise seii = (Qc + Qo - Qt) ficm;( 26)
depositing and going out material with the air from the
filter. (Qk + Qc + Qo - Qt) fise (1 - seii) = Qk fik. (27)

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Summing both sides of these equations for all the From the expression (38) we must also exclude the
factions, we get: value f oQo . To do this, perform a similar inverse
i
m transformations, starting with point 12. With the help of
Qc + Qo - Qt = (Qk + Qc + Qo - Qt)
∑ f jse seii ; (28)
expressions (25) and (24) the relation (31) is:
i =1
m Qo fio = (Qc + Qo - Qt) fism oii = (Qk +Qc + Qo - Qt) fise seii oii =
Qk = (Qk + Qc + Qo - Qt)
∑ f jse (1 − seii ) ; (29)
= seii oii (Qk + Qc + Qo - Qoc - Qt) fi(4) + seii Qoc fio. (39)
i =1
k fise (1 − seii )
fi = . Next using (8)...(17), (20), (23) we get:
m (30)
∑ fi se
(1 − seii )
Qo f io =
seii oii (1 − sii aii fii cii )(1 + ? ) 1
fi Q1. (40)
i =1
1 + P − seii oii (1 + (1 − fii ) ? )
The deposition of cement in cyclone-precipitators
characterized by a matrix O = (oii):
Substituting equation (40) into (39) we get:
(Qc + Qo - Qt) fism oii = Qo fio; (31) (1 − seii )(1 − sii aii fii cii )(1 + ? ) 1
Qk fik = fi Q1. 1(41)
1 + P − seii oii (1 + (1 − fii ) ? )
(Qc + Qo - Qt) f i
sm
(1 - oii) = (Qc - Qt) f = Q f . i
2
2 i
2
(32)

Summing both sides of these equations for all the Dividing both sides of equation (41) on Qk, we get:
factions, we get: 1 (1 − seii )(1 − sii aii f ii cii )(1 + ? ) 1
fi k = f . (42)
1 1 + P − seii oii (1 + (1 − fii ) ? ) i
m 1−
Qo= (Qc + Qo - Qt)
∑ f jsmoii ; (33) kc
i =1
fio oii Summing both sides of equation (42) for all the
o
fi = m
m (34)
∑ fi cm
oii
factions and given that,
∑ f jk = 1 we get:
i =1 i =1
m
Q2= (Qc + Qo - Qt)
∑ f jsm (1 − oii ) (35) 1
= 1− ∑
m
(1− seii )(1− siiaii fiicii )(1+ ? ) 1
fi . (43)
i =1 kc 1+ P − seiioii (1+ (1− fii )? )
i=1

f ism (1 − oii )
fi 2 = . Substituting (42) and (43) into equation (36) after
m (36)
∑ fi sm
(1 − oii ) simple transformations we obtain:
i =1 m (1 − se jj )(1 − s jj a jj f jj c jj )(1 + ? )
For the closure of the matrix equation (7), which is the fioc −
fi1 = ∑( f joc − Pij ) 1 + P − se jj o jj (1 + (1 − f jj ) ? )
f 1j .
basis of the model of grinding is necessary to express the j =1

dispersion of grit through the dispersion of the original (44)

material. This is feasible, since point 11 reverse
m
transformation. Substituting into equation (27) the relation
(25) and then in (24) we get:
Here fioc = ∑ Pij f 1j - calculated (by the grain structure
j =1

Qk fik = (1- seii) Qoc fio+(1- seii)(Qoc- Qa) fi(1) + of original material), the quantities that determine the
(1- seii) Qa fia(1- sii)+(1- seii)(Qa- Qs) fis(1- cii) particulate composition of the product after grinding,
(1- seii)(1- fii)(Qa - Qs - Qy) fiym+(1- seii)(1- fii)(Qo- Qoc) fio. resulting in an open circuit. Elements of the matrixes
(37) characterizing the operation of ball mill pii, aspiration aii,
aspiration shaft sii, cyclone to clean the aspiration air cii,
Then with the help of equations (8)...(12) and (18) we get: filter fii, separator seii, cyclone separators, oii, as well as air
leakage rate p must be specified.
(1 − seii )(1 + (1 − fii ) ? ) o Then from the matrix equation (44) can be obtained
Qk fik fi Qo +
1+ P (38) system of m equations with known coefficients, the
+ (1 − seii )( solution of which gives the dispersed composition of f 1 a
1 − sii aii fii cii fi1Q1.) i

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closed circuit system load of the grinding circuit based on They allow the co-regulation of their operation
a ball mill. Knowing the values with the f 1 help of (43) modes for maximum performance of the product specified
i
quality.
can find the load on the separator defined by the
coefficient kc. By given a load mill Qse and circulation rate
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